Monobloc acetabular reamer section

Abstract

A system, method and/or reamer driver device is provided having a domed external surface and a domed internal surface being concentric to the domed external surface thereby defining a hollow dome or section thereof. At least one cutting tooth is disposed on the hollow dome or section thereof. The cross-sectional thickness T measured substantially perpendicular to the crest of the at least one tooth is greater than the radial distance t between the external and internal domed surfaces. The hollow dome or section thereof is made using an injection molding process or a 3D printing process.

The invention claimed is: 
     
       1. A cutting blade comprising a section of a domed external surface and a section of a domed internal surface being concentric about a rotational axis to the section of the domed external surface thereby defining a section of a hollow dome, wherein at least one cutting tooth comprising a cutting edge, a crest and a cutting surface is disposed on the section of the hollow dome and wherein by virtue of the cutting surface having been formed by an injection molding process or a 3D printing process, a cross-sectional thickness T measured substantially perpendicular to the crest of the at least one tooth is greater than a radial distance t between the section of the external and internal domed surfaces, wherein further the section of the external and internal domed surfaces of the section of the hollow dome are interrupted by at least one portion of a hole passing therethrough defining the cutting edge and the cutting surface of the at least one cutting tooth, the cutting edge comprises the crest, wherein the at least one portion of the hole passing therethrough is cylindrical. 
     
     
       2. A cutting blade comprising a section of a domed external surface and a section of a domed internal surface being concentric about a rotational axis to the section of the domed external surface thereby defining a section of a hollow dome, wherein at least one cutting tooth comprising a cutting edge, a crest and a cutting surface is disposed on the section of the hollow dome and wherein by virtue of the cutting surface having been formed by an injection molding process or a 3D printing process, a cross-sectional thickness T measured substantially perpendicular to the crest of the at least one tooth is greater than a radial distance t between the section of the external and internal domed surfaces, wherein further the section of the external and internal domed surfaces of the section of the hollow dome are interrupted by at least one portion of a hole passing therethrough defining the cutting edge and the cutting surface of the at least one cutting tooth, the cutting edge comprises the crest, wherein the at least one portion of the hole passing therethrough is conical and therefore tapered. 
     
     
       3. A cutting blade comprising a section of a domed external surface and a section of a domed internal surface being concentric about a rotational axis to the section of the domed external surface thereby defining a section of a hollow dome, wherein at least one cutting tooth comprising a cutting edge, a crest and a cutting surface is disposed on the section of the hollow dome and wherein by virtue of the cutting surface having been formed by an injection molding process or a 3D printing process, a cross-sectional thickness T measured substantially perpendicular to the crest of the at least one tooth is greater than a radial distance t between the section of the external and internal domed surfaces, wherein further the section of the external and internal domed surfaces of the section of the hollow dome are interrupted by at least one portion of a hole passing therethrough defining the cutting edge and the cutting surface of the at least one portion of the cutting tooth, the cutting edge comprises the crest, the cutting blade further comprising a portion of a visible parting line. 
     
     
       4. A method for manufacturing a cutting blade comprising a section of a hollow dome, the method including the steps of:
 a) injection molding or 3D printing of the section of the hollow dome of the cutting blade including at least one tooth projection; 
 b) sintering of the hollow dome of the cutting blade. 
 
     
     
       5. The method of  claim 4 , further including the step of machining of at least one portion of a hole in the at least one tooth projection to create a cutting edge of an at least one tooth. 
     
     
       6. The method of  claim 4 , wherein the injection molding is injection molding of metal powder (MIM). 
     
     
       7. The method of  claim 4 , wherein the 3D printing is 3D printing of a blend of metal powder and plastic. 
     
     
       8. The method of  claim 4 , further including the step of heat treatment of the cutting blade. 
     
     
       9. The cutting blade of  claim 4 , wherein a facing surface of the cutting edge is formed or reformed by drilling or milling. 
     
     
       10. A cutting blade comprising a section of a domed external surface and a section of a domed internal surface being concentric about a rotational axis to the section of the domed external surface thereby defining a section of a hollow dome, wherein at least one cutting tooth comprising a cutting edge, a crest and a cutting surface is disposed on the section of the hollow dome and wherein by virtue of the cutting surface having been formed by an injection molding process or a 3D printing process, a cross-sectional thickness T measured substantially perpendicular to the crest of the at least one tooth is greater than a radial distance t between the section of the external and internal domed surfaces, wherein further the section of the external and internal domed surfaces of the section of the hollow dome are interrupted by at least one portion of a hole passing therethrough defining the cutting edge and the cutting surface of the at least one portion of the cutting tooth, the cutting edge comprises the crest, wherein the at least one portion of the hole passing therethrough lacks sharp corners. 
     
     
       11. The cutting blade of  claim 1  further comprising at least a portion of a visible parting line. 
     
     
       12. The cutting blade of  claim 2  wherein the at least one portion of the hole passing therethrough lacks sharp corners. 
     
     
       13. The cutting blade of  claim 2  further comprising at least a portion of a visible parting line. 
     
     
       14. The cutting blade of  claim 3  wherein the at least one portion of the hole passing therethrough lacks sharp corners.